1. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 1 NuMI Horns Experience Horns were put in target hall June 2004 1 st run with beam Jan. 2005 Accumulated: 9.2 Million pulses 820 MWhr integrated beam power Still running with first set of horns

2. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 2 Horn system – 2 horns (shown in work cell, hanging from support module)

3. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 3 Horn Inner conductors Parabolic inner conductors: 3 Tesla max. magnetic field 3 m active length each horn Inner conductors welded together at FNAL by lead engineer Kris Anderson

4. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 4 Horns connected in series with power supply by strip-line Peak current: 200 kA maximum Pulse width: 2.3 m-sec half-sine wave Repetition rate: 1.87 sec

5. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 5 Horn environment Horn inner and outer conductors are cooled via internal water spray. We are running slow Argon gas purge through horns and water system. Reduce corrosion, prevent buildup of flammable level of hydrogen. Horn modules and strip-line are cooled with re-circulating air system, which also cools baffle, target carrier, and shielding. Air system keeps relative humidity down to 50% - 60% Air exchange (leak) time constant is of order 45 minutes

6. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 6 NuMI Horn current Current stability is excellent, pulse-to-pulse RMS < 0.1 % (spec. 0.4%) Horn field stability also shown by neutrino spectrum stability (see target talk)

7. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 7 Problems ? The most useful part of NBI is to hear what DIDN’T work, so:

8. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 8 Horn 1, after a year of beam

9. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 9 Horn 1, after a year of beam

10. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 10 Use of ceramics in Horn Where usedMaterialComment Ring separating inner, outer conductors Alumina, knife-edge sealNo indication of problem, no color change Water spray line insulatorsAlumina, braze jointTwo failures, suspect braze but need autopsy Bdot coil magnetic field monitors Yttria stabilized zirconiaNo indication of problem, Bdots still operating Inner conductor support spiders Partially stabilized zirconiaNo indication of problem, can’t see them Stripline insulatorsPartially stabilized zirconiaNo indication of problem, color change ivory > brown Instrumentation cable insulation Alumina ceramic fiberNo indication of problem, no color change

11. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 11 Use of metals Where usedMaterialComment Horn outer conductors, target rails Anodized aluminumLooks in excellent condition Water lines, bolts, mechanical parts Stainless steelLooks in excellent condition FastenersTitaniumLooks in excellent condition Main module, T-block shieldPainted steelLooks in very good condition Carrier frame, Target casingAluminumLooks OK, some surface degradation Horn inner conductorsNickel coated aluminumEnd-cap looks good, Parabolic section looks bad Module support, ceramic shell Steel, invarCorrodes Alignment rails, gear boxesBlack oxide coated steelCorrodes Module tops, some shieldingNickel coated steelLarge nickel flakes

12. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 12 Use of thermocouples Used type J thermocouples with ceramic connector for remote connection The iron pin on the connector corrodes – need to look for something else

13. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 13 Bdot field monitoring coils inside horns The wet environment in the horns has been problematic for the un-insulated wiring. After implementation of better coherent noise cancellation circuit, the three b-dot coils on each horn run well enough to check field stability. But would totally isolate these from water in future.

14. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 14 Inner Conductor Corrosion Why is corrosion in general so bad ? Ionized air produces ozone, nitric acid, … Note the water from dehumidifying the re-circulating air has PH of 2.6 Why does end bell of horn look great, and parabolic section horrible ? Don’t know, but… End cap is in 18 mph wind Parabolic section is relatively dead spot for air motion Bad air may be building up in dead spot

15. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 15 Have brazed ceramic electrical insulators on horn water lines They are strain-relieved with invar+ceramic clam-shells On horn 1, developed a 7gal/day water leak on line to spray header On horn 2, leak on suction line drew air in, reducing amount of water ejector pump could remove from horn collection tank Both ceramic sections were successfully replaced Speculate braze corrodes… planning to switch from brazed to a shrink-fit ceramic/steel connection for spare horns Two horn water system leaks Horn 2 in February 2006, Horn 1 in August 2006

16. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 16 Ejection pump to suck up water Check valve Ceramic electrical insulation hole here in suction line drawing in air reducing water suction Water collection tank Cut suction line for repair

17. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 17 New ceramic Water suction line Horn 2 going back in shielding after suction line replacement

18. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 18 Horn 2 ground fault - - loose foot on horn Owl shift Thurs. Sept. 29, 2005 intermittent horn trips. Owl shift Sat. Oct. 1, hard ground fault of 1 ohm. -removing stripline fingers Horn 2 + stripline block -when Horn 2 moved to work cell ground fault cleared -foot left behind in chase, nut had vibrated off -scorch marks seen under foot Moved old foot, installed new foot Horn 2 before beam 1.5 inch clearance foot to floor

19. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 19 Visual inspection of horn 2 Oct 2005 (note, somewhat more green right now) Zirconia Ceramic changed color - ivory to coffee Alumina Ceramic unchanged Nickel-coated aluminum inner conductor shows slight discoloration - bottom covered by rust dust Al cross-hair - lots of surface corrosion Anodized Al outer conductor is good Stainless parts look OK Other horn 2 feet corroded in place No obvious problem spots New

20. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 20 Strip-line block flake problem Strip-line shielding block is steel with nickel coating Nickel is flaking off, sometimes shorts stripline but has always burned off after 1 to a dozen pulses We have rebuilt spare strip-line block with non-flaking technology but haven’t needed to use it yet

21. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 21 Horn spray flowmeter with beads Horn nozzle for inner conductor is eliptical ~40 mils short direction (48 total) outer conductor nozzles round, 25 mils diameter (19 total) plus two side-spray nozzles June 30, 2006, resin beads from deionization bottle clogged the water spray lines on Horn 1 New, uncontaminated beads Beads are ~ 20 mils diameter

22. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 22 The gravity un-assisted check valve When water skid was turned off for maintenance, beads floated backwards through improperly mounted check valve

23. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 23 Check valve That didn’t check

24. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 24 Cleaning Out Resin Beads Fan push, water-in-barrel filter, vacuum suck

25. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 25 Of course, many things worked Beam to horn timing was within spec. on first pulse, and totally stable over run. Horn 1, Horn 2, and Target were aligned by survey on straight line, confirmed by beam scans using the horn “cross-hairs” beam alignment monitor. (The “cross-hairs” proved to be important). Horn 1 motor drives worked as planned. Remote water connections worked as planned. Remote strip-line connection worked as planned. The shielding and remote handling systems worked as planned. This was a real 3D jig-saw puzzle. The re-circulating air system balanced; measurements show reasonable flow through each of horn strip-line penetrations, around module walls, by target, around shielding pile outside walls, etc. Measured vibration of horns hanging on modules was small. Residual radiation was about as expected – important for repairs.

26. NuMI NBI2006 September 6, 2006 NuMI Horns Experience Jim Hylen / FNAL Page 26 Conclusion NuMI horn system has made it through 1 st year of operation, although some repairs have been necessary. As described in the target talk, the horn system produced the desired neutrino spectrum, and the neutrino spectrum was also very stable over time !!! We are learning on the job how to improve the hardware - and look forward to lots more running !